Powering change

trends in automation The Festo customer magazine 1.2012

Inspiration

Free from resources Interview with Prof. Dr.-Ing. Egon Müller, Chemnitz University of Technology

Compass

Environmental flight Solar energy boost, cheaper batteries on the way

Synergies

Hungary drives ahead The outlook is good for companies in the automotive industry

Cover story

Powering change Ideas for greater energy efficiency

On course for energy efficiency Set your course for maximised savings potential. On board you’ll find products and solutions, intelligent configuration, tailored services as well as training and consulting.

www.festo.com

Time to act Energy is something we use every minute of every day. Sometimes we don't give it much thought; other times it may preoccupy us, whether we are responsible for ensuring its supply, use it to provide food, to travel places or wonder how to pay for it. Another reason for concern may be related to global warming, the environment or health issues associated with obtaining and using fuel. In short, we are affected by energy, on whatever level and in whatever big or small way. Energy usage is also a big concern for factories. For many energy consumption is the largest contributing factor to increasing production costs and rising faster than labour costs. How do we use fuel more efficiently, how can we prevent losses in supply systems, what can we do to use less and how can we make or convert energy-inefficient equipment into energyefficient ones? In this issue of trends in automation we focus on how factories can change the way they manage their energy requirements to save money and resources.

Rich Huss, President and CEO Festo USA

In an interview with Dr. Mueller we read about his thoughts on cutting consumption in very interesting ways. These include considering energy usage right at the design stage, using software, regulating power requirements to match the flux of slower and busier work times. "Smart" systems can also help to make better use of natural lighting, air and water by monitoring and adjusting usage carefully. We also explore some rather inventive uses of solar power and batteries that could prove interesting for the future. The modern world is inextricably linked to energy. As world population grows and standards of living improve, the topic of how we source and use energy becomes significant and could have far-reaching consequences. Not only do we need to develop clean renewable ways of obtaining energy, we also need to change our behaviour and find new ways of using it more efficiently. We have the tools and the time to act is now. In this edition of trends in automation you will find plenty of food for thought and action!

Rich Huss

Photo: GeoEye

Cover story Bird’s eye view of the Gemasolar solar power plant in Spain: The plant is revolutionising electricity generation using solar energy (see back page). This groundbreaking technology symbolises the dawning of a new era in energy efficiency – and is at the heart of several initiatives in industry and automation technology. In this issue we look at the objectives, applications and results of these efficiency measures.

trends in automation

1.2012

Editorial 3 Panorama 6 Festo worldwide 38 About this magazine 41 Soft Stop 42

14

The solar plane “Solar Impulse” is set to circumnavigate the globe in two years’ time – with no fuel and no harmful emissions.

Compass

8

“The best energy efficiency measure is, quite simply, to save energy.”

Inspiration No race for resources Energy-efficient production concepts are preparing companies for tomorrow’s competition. Prof. Dr.-Ing. Egon Müller talks about savings potential of up to 50% over the next decade. 8

Batteries move up a gear Electric cars are becoming more popular, but expensive batteries take the fun out of driving. The automation industry is therefore working on concepts for low-cost battery production. 12 Sun-fuelled wings Fuel prices have exploded and rising costs are having an impact on air travel. Environmentally-friendly forms of propulsion are opening up new perspectives for altitude flight with renewable energy. 14

1.2012 trends in automation Contents 4 – 5

16

Twenty per cent of a car’s entire energy consumption over its life cycle comes from the production process.

Impulse Cover story Powering change The will is there, but the way is unclear. When it comes to actual implementation of energy efficiency measures, plant manufacturers and operators aren’t sure where to start. Germany is leading the way with initiatives that are driving more efficient use of the earth’s limited resources. 16 Further related articles No race for resources 8 Batteries move up a gear Sun-fuelled wings 14 Sunny side up 32 Every gram counts 36

12

Skin from the factory Touch, heat, breathing – the skin is our most important organ. Four Fraunhofer Institutes have developed a fully automated process for producing skin equivalents for medical applications. 22

32

For Oerlikon Solar, the outlook for thin-film silicon technology in photovoltaic modules is good.

Synergies A country on the move Hungary is a country deeply rooted in European history. Despite the negative political headlines, the business outlook remains promising. 26 Tooth by tooth Modern transmissions must be able to withstand extreme loads. Ready-toinstall pneumatics are making the production of bevel gears faster and safer. 30

Sunny side up Oerlikon Solar is overcoming the upheaval in the sector with quality and innovation. Automation technology from Festo guarantees perfect handling of large sheets of glass. 32 Every gram counts Tonnes of waste are produced in tin plate production. Huber Packaging Group and Festo Didactic have significantly improved material efficiency thanks to material flow analysis. 36

Energy excellence Standing 508 metres tall, the world’s tallest office building is truly a sight to behold. In July 2011, the Taipei Financial Center, Taipei 101, also became the world’s tallest green building, achieving Leadership in Energy and Environmental Design (LEED) Platinum Certification under “Existing Buildings” for outstanding energy efficiency measures.

Over a 20-month period, the office building underwent a series of optimisation measures and energy consumption was significantly reduced. With 101 floors above ground and fi ve below ground level, this “green building” is now achieving annual energy savings of 10 per cent. Current consumption was reduced by 4.8 million kilowatt hours,

water consumption was reduced by 28,000 tonnes and there are now 1,261 fewer tonnes of waste produced than there were before the efficiency measures were introduced. Taipei 101’s energy consumption is now up to 30 per cent lower than that of an average building, resulting in annual savings of around 700,000 US dollars.

Phot Pho hoto: Danie ho Danie nie iel M. M Shi Shih

Interview

No race for resources Egon Müller is one of the leading experts in innovative production structures and factory concepts. The Professor of Factory Planning and Factory Management at the Chemnitz University of Technology believes that savings potential of up to 50% can be realised over the next decade through environmental production factors. In this interview he explains the importance of staying out of the race for energy resources.

trends in automation: Professor Müller, you see a savings potential of between 30% and 50% of the total consumption of material and energy resources. Is this figure not too high? Prof. Egon Müller: To back up this statement, we need to first remind ourselves of a well-known principle of physics. Energy can be transferred between systems, but cannot be created or destroyed. It can only be converted from one form of energy into another. Furthermore, energy conversion between different forms of energy and energy levels must take place in one direction and cannot be reversed. If you look at a factory as a “total energy consumption system”, in which a wide variety of energy conversion processes take place, the potential you referred to can be achieved systematically. When it comes to

About the person

Prof. Dr.-Ing. Egon Müller Egon Müller heads the Department of Factory Planning and Factory Management at the Chemnitz University of Technology. He and his team of 30 staff members work on the development of future production structures and new factory concepts in mechanical and plant engineering and for the automotive industry and its suppliers. These include flexible and versatile factories as well as non-hierarchical regional production networks. The department offers extensive expertise in the field of computer-based factory planning, modelling and simulation as well as energy-efficient factory planning. www.tu-chemnitz.de/mb/fabrplan/englisch

the consumption of material resources, the use of new materials and their cycles – in other words their reuse – is of major importance along with new technological methods. For factory planning and operation, this means generating new concepts that, for example, bring together mechanical engineering and process engineering in order to create these cycles. trends in automation: In your book “Energieeffiziente Fabriken planen und betreiben” (Planning and Operating Energy-efficient Factories), you show how the potential for energy savings can be exploited systematically. What are the key points here? Müller: I could refer to the necessary holistic approach, but that wouldn’t be any more useful than merely suggesting a systematic approach. A factory is first and foremost a group of people who use the available machines and equipment to create products from materials. These processes are also planned by people and are therefore to be anticipated. We must develop appropriate competencies and train the people in the factory to realise this potential systematically using the methods and tools provided. Along with this aspect, a holistic view of the supply, conversion, transfer, and use of energy as well as its optimisation in the factory play a key role. trends in automation: To what extent can energy efficiency be made a strategic competitive factor for a company? Müller: Continuously rising energy prices and the associated direct cost effect will be a major issue for companies in the future. Issues surrounding the availability of and access to energy resources will also become a strategic success factor for companies. Looking at the forecasts for future energy demand by energy source and economic area for the period up to 2030, it is already clear that companies in a position to opt out of this race for energy resources will have a major competitive advantage. It is also clear that the best energy efficiency measure is, quite simply, to save energy.

1.2012 trends in automation Inspiration 8 – 9

“The best energy efficiency measure is to save energy.” Egon Müller, Chemnitz University of Technology

trends in automation: To what extent can a factory plan for and implement energy self-sufficiency? Müller: Using a holistic approach, it is feasible for the planning of new factories and relevant for the planning and realisation of factory areas or extensions. The energy-efficient plant extension project in St. Ingbert/Rohrbach, for which Festo won the Energy Efficiency Award 2008, is a good example of the type of development that has taken place in recent years. Since then, many technologies and possibilities have undergone further development and are now available for integration in suitable planning concepts. This also includes potential that can be realised through the use of renewable energy. trends in automation: What sector do you see as the leader in energy efficiency and why? Müller: Based on my own experiences, automotive manufacturers and their major suppliers are leading the way. The huge rise in energy costs is by no means the only incentive. Marketing is another major consideration, as it focuses not only on the environmentally-friendly and resource-efficient nature of the products themselves, but also on their manufacture and, consequently, the factories in which they are produced. It is important that the entire product life cycle be taken into account, particularly the manufacture and use phases. trends in automation: Is the automotive industry a good example for other sectors? Müller: Basically, yes. In some cases the automotive industry is more than just taking the lead role; the major significance of the industry means it has a direct influence on other sectors. This applies to mechanical and plant engineering, control and automation technology as well as electrical engineering and drive technology. trends in automation: What energy-efficient projects is your institute currently involved in and what conclusions have you drawn from your research?

Müller: In the cluster of excellence “Energy-efficient Product and Process Innovations in Production Engineering” (eniPROD), we are working on a “Logistics and Factory Planning” subproject, which aims to develop methods for factory planning with a focus on energy efficiency and software systems to support the planning process. This research has already produced a conceptual framework for a holistic energy efficiency model. With this model, knowledge can be created, prepared and made available in a systematic manner on the one hand, and competence development and training can be implemented on the other. In another research project with a stronger technological focus, we are working on the measurement and recording of energy consumption in complex factory structures. Initial findings in relation to measuring systems and their benefits have already been applied to practical solutions. trends in automation: What does a busy man such as yourself like to do in his spare time? Müller: When I have the time, I like to work on my 1976 vintage car in my garage. During the summer, when the weather is good, I enjoy going for drives or taking part in vintage rallies. I also like to read books about automotive engineering. Issues such as the historical development of factories create a link between my work and my spare time.

1.2012 trends in automation Inspiration 10 – 11

Automation optimises e-mobility

Batteries move up a gear There are currently 2,300 electric cars on Germany’s roads. This figure is set to reach one million by 2020. The industry is currently dealing with the crucial question of how to make the leap to low-cost, high-volume battery production. The automation industry has some answers.

I

n order to make electromobility more accessible for the broader market, the cost of batteries used in electric vehicles needs to come down. They are still one of the biggest cost drivers in electromobility. The problem is that battery production is still predominantly a manual process with a large number of individual steps.

Competence cuts costs “Between 30 and 40 per cent of the value added in purely electric vehicles is due to the battery,” says Michael Karcher, Head of the industry segment Electronics and Solar at Festo. “If we are to eventually have efficient mass production, we need to set up technologically flexible electrode and cell production for the manufacture of battery prototypes with a high degree of standardisation and automation. This will allow production costs to be reduced and ensure the quality of the results.” This demands effective and reliable automation competence at all levels. Mechatronic solutions, which integrate expertise from different areas of process and factory automation and transfer it to the latest technologies in battery production, look promising. Innovation with mechatronics “Our customers from the automation industry have a good understanding of the automotive sector when it comes to their current field of activities. However, when it comes to the optimum conditions for battery production engineering, they are more or less starting from scratch,” says Karcher. In order to fundamentally

Ph Phot hotto: o Daiml i ler A im AG G

redefine processes you need innovators like mechatronics engineers and a willingness on the part of companies to innovate. This is exactly what happened in the case of automation system supplier and plant manufacturer ads-tec. The company, which is based near Stuttgart, develops automated production systems for high-performance lithium-ion energy storage devices. Protection of sensitive cells For the FUEL project initiated by the Federal Ministry of Education and Research (BMBF), ads-tec first developed a production method for automating the bonding, feeding and handling of cells on a laboratory scale. According to Head of Automation Dr. Peter Korff, the aim was to provide production facilities that would allow the fast, low-cost production of cells and battery systems. “Lithiumion cells are sensitive. We must make sure that we maintain cell quality during the process and take care not to damage or contaminate them, particularly during handling. Because we have to create a whole new set of conditions for the accumulator production technology, we are open to new solutions and ideas. For handling the lithium-ion cells, we

worked with Festo to devise a new frontend solution with an air bearing, which was previously only used for the solar or electrical industry,” explains Dr. Korff. Objects slide evenly Both the solar and electrical industries use the air bearing ATBT from Festo for the contactless transport of sheets of glass and delicate film. A layer of air on the fine surface allows objects to glide evenly. For ads-tec, the engineers from Festo used the so-called reversal effect, with an extensive vacuum for the handling of battery packs in the production system. “With conventional solutions we could only grip the cells in certain places using vacuum generators, which meant that reliable holding of the cell could not be guaranteed,” says Michael Karcher. Because the air bearing grips the entire surface, the bonding process is no longer prone to failure caused by production.

1.2012 trends in automation Compass 12 – 13

Michael Karcher, Head of industry segment DE Electronics and Solar, Festo

One more question

People want e-mobility According to a study on electromobility by TÜV Rheinland, the level of acceptance for electric cars is growing worldwide. This applies in particular to the emerging markets of China and India, where mobility is also rising. 92% of people in India and 88% in China are willing to consider an electric car if buying a new car within the next five years. In Germany and the USA, the figure is lower at 57%, with the figures for the UK and France being about the same.

ads-tec production system: Automated bonding, feeding and handling of lithium-ion energy storage devices.

Air bearing ATBT in the bonding process: Festo also delivers air supply and air/vacuum preparation with corresponding valve and control intelligence depending on the degree of automation.

trends in automation: Solutions with similar requirements to those of battery construction already exist in the manufacture of carbon composites. Is it possible to transfer this technology? Michael Karcher: Absolutely, yes. Lightweight design plays a crucial role in the production of electric vehicles. It is a good starting point for our engineers, who are familiar with the requirements for handling flexible materials in the food and textile industries. In those environments it is important to grip bulky materials carefully, to observe the fibre orientation during handling and placement and to avoid unnecessary stress on the structures. This expertise can be applied very effectively to the automation of battery production.

P o: Solar Phot S olar Imp Impulse ulse/Jea /Jean n Revill Revillard ard

Energy-efficient flight

Sun-fuelled wings Increasing passenger volumes in international air travel have intensified the search for energy-efficient drive forms. Many of the current developments share the same ambitious goal – to fly using renewable energy.

T

he history of flight has been shaped by pioneers such as Otto Lilienthal, the Glider King, Louis Blériot, the first man to fly across the English Channel, and Amelia Earhart, the first woman to fly solo across the Atlantic. Today’s pioneers are working hard to develop a whole new generation of energy-efficient aircraft.

Lightweight aircraft sets milestones Two of these pioneers are balloonist and adventurer Bertrand Piccard and his partner André Borschberg. Their aim is to circumnavigate the globe in 2014 in their solar plane “Solar Impulse”, using only solar energy. The first crucial steps in the pioneers’ ambitious plan have

1.2012 trends in automation Compass 14 – 15

Energy efficiency in its highest form: With around 12,000 solar cells, the Solar Impulse HB-SIA is the first solar aircraft to fly day and night without fuel.

already been successfully completed. In July 2010, Solar Impulse made the first night flight in the history of solar aviation, lasting 26 hours. In May 2011, the solar-powered lightweight aircraft proved its ability for short-haul flights with a 630-kilometre trip from Payerne in Switzerland to Brussels. For Piccard, who in 1999 made the first non-stop round-the-world balloon flight, this represents a major milestone in aviation history. It was this world record trip that inspired him to develop Solar Impulse. After around 20 days of continuous flying, the balloon’s fuel supply almost ran out shortly before reaching its destination. With the sun as an inexhaustible energy source, this should never happen again. Energy from 12,000 solar cells For the round-the-world trip in 2014, Piccard and Borschberg are building a new machine specially adapted to longhaul conditions. It will even exceed the already impressive values achieved by the current prototype HB-SIA. The HB-SIA is a cantilever high-wing aircraft with four electric motors, which power the twin-bladed propellers at a speed of 200 to 400 rpm. Current is supplied by around 12,000 solar cells. With a wingspan of 64 metres, the Solar Impulse is almost as wide as an Airbus A340. Whereas the jet has an average take-off weight of 300 tonnes, the solar aircraft weighs 1,600 kilograms at takeoff, which is not much heavier than an average-sized car. Solar Impulse reaches a maximum altitude of 8,500 metres at an average flying speed of 70 kilometres per hour. Any comfort must take second place to the required drive energy, however. Passengers must wear warm clothing to protect themselves against the cold. www.solarimpulse.com

A brave vision According to aircraft manufacturer EADS, the passenger aircraft of the future will be battery-powered. EADS presented the “VoltAir” fully electric drive concept at the Paris Air Show Le Bourget 2011. This research project brings the vision of a zero-emissions, ultralight aircraft a step closer to becoming a reality. This could feasibly happen within the next 20 years. VoltAir passengers will benefit from the extremely low noise levels of the engines.

P o: Phot o EADS E ADS

Hybrid takes off Siemens, Diamond Aircraft and EADS have developed the world’s first aircraft with serial hybrid electric drive. The new drive train was tested in the “DA36 E-Star” motor glider. The E-Star uses a serial hybrid electric drive, which until now was only found in cars. A 70 kW electric motor from Siemens powers the propeller. The required electricity is supplied by a small engine with a generator. Fuel consumption is very low since the combustion engine always runs with a constant low output of 30 kW. A battery system provides the increased power required during take-off and climb.

Photo: Siemenss

Naturally efficient A unique undertaking in distance records starts every year in western Alaska, when the world’s best long-distance flier prepares for a very special non-stop journey to the other side of the world. The most resilient bar-tailed godwits can fly the 11,500 kilometres from America’s far north to New Zealand in just 10 days without stopping. This amazing feat is possible thanks to the perfect combination of bodyweight, aerodynamics and wingspan as well as an intelligent choice of route.

Efficiency initiatives

Powering change When it comes to actual implementation of energy efficiency measures, many plant manufacturers and operators aren’t sure where to start. Numerous efficiency initiatives have been introduced by German industry to lead the way. They can power change by helping companies to drive international efforts for more careful use of the planet’s limited resources.

1.2012 trends in automation Impulse 16 – 17

Savings potential in automotive engineering: Production accounts for 20% of the energy consumed by a vehicle over its entire life cycle.

T

here are no indicators to suggest a reversal of the trend of rising energy prices in the medium term. This is partly due to the huge growth in demand for energy from emerging BRIC countries and the finite supply of fossil fuels. The uncertainty as to whether fossil fuels can ever be fully replaced by renewable energy sources is also a contributing factor. The figures speak for themselves. In the past decade, industrial energy prices have risen

by approx. 12.5% year on year. These costs are therefore rising between two and four times faster than personnel costs, which are another key strategic cost for businesses. Exploding energy prices It is surprising that so many companies do not have a detailed breakdown of their energy costs. Although most are aware of the energy costs per year, energy consumption is rarely documented

with a view to evaluating cost-cutting measures relative to total expenditure. It is also common practice to add energy costs to fixed costs or variable production costs rather than to report them individually. Initiatives such as Green Carbody, Blue Competence, Energy Efficiency in Pneumatic and Electric Production Systems (EnEffAH), the German Electrical and Electronic Manufacturers’ Association (ZVEI) and the Society for Measurement and Automatic Control (VDI/

Energy efficiency@Festo Every industrial application has its own specific requirements when it comes to technical and financial criteria. Examples include speed, load capacity, precision, efficiency or robustness as well as acquisition costs (price, commissioning, installation) and operating costs (maintenance, service life, energy costs). The importance of energy efficiency can vary depending on the application. “The task at hand must be clearly defined before deciding whether to choose electric or pneumatic drive technology – or a mixture of both,” explains Festo energy efficiency expert Dr. Axel-Andreas Gomeringer. Even a small number of measures can have a positive effect on energy efficiency. These include Energy Saving Services, training courses, air-saving circuits, weight reduction and energy recovery as well as the correct sizing of drives or the reduction of leakage, pressure levels, tube volumes or friction. Customers specify the application and experts from Festo then check and find the most efficient alternative. The “Energy Efficiency@Festo” brochure provides a useful introduction to this topic. Tools for the optimum configuration of drives and the new energy efficiency calculator are available on the Internet. These allow users to calculate the costs for compressed air production using different variables and to determine the savings potential for compressed air consumption. www.festo.com/energyefficiency

Leakage detection with ultrasound detector: With Festo Energy Saving Services, companies have energy consumption under control.

1.2012 trends in automation Impulse 18 – 19

“The objective of the alliance is to achieve energy savings of up to 50% during the automotive production process.” Dr. Jan Bredau, Head of Development Systems, Festo

VDE GMA) as well as the Energy Saving Services from Festo that are used by many companies are helping to ensure that there is more clarity with respect to energy costs and are thus paving the way for greater energy efficiency. Green Carbody The production process alone accounts for 20% of a vehicle’s entire energy consumption over its lifetime. To reduce this percentage, 60 companies in Germany joined forces to create the “Green Carbody Technologies” innovation alliance. “The objective of the alliance is to achieve energy savings of up to 50% during the automotive production process,” says Dr. Jan Bredau from Solutions Product Management at Festo. In the “planning the efficient use of compressed air” subproject, Volkswagen, Boge Compressors, Festo and the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) aim to save energy in compressed air applications. Compressed air is used in these systems primarily for welding tongs, grippers, toggle lever clamps, pin pulling cylinders and other cylinders. More is required for the process, for example during laser welding. Analysing compressed air consumption Energy consumption can be significantly reduced through detailed analysis of compressed air consumption in body construction, better coordination between the generator and consumer sides, simulation-based configuration as well as energy monitoring and diagnostics. Consumption data is recorded, solutions for improving energy efficiency are determined and losses due to planning and operation are identified. Tools for estimating compressed air consumption during the planning phase help to ensure optimum and energy-efficient coordination between the generator and consumer sides in compressed air applications. “Other automotive manufactur-

ers have now also expressed an interest in these successful energy-saving tools,” explains Werner Reichelt, Head of Automotive Management at Festo. 50% less energy Electric motors account for around 70% of all industrial energy requirements. However, there is no reliable differentiation for the energy consumption of electric motors in handling technology, nor is there precise data for the distribution of compressed air technology.

The efficiency initiatives introduced by German industry are being used both individually and collectively to identify savings potential. They can help companies to drive sustainable business practices and efficient use of resources. The net result is an investment that is good for the environment and the company balance sheet. www.eneffah.de www.bluecompetence.net www.vdi.eu

The experts working on the joint project “Energy Efficiency in Pneumatic and Electric Production Systems” (EnEffAH) expect savings of up to 50% for electric motors and compressed air systems. Supported by the Federal government, EnEffAH is drafting energy-saving concepts and plant optimisation procedures for pneumatic and electrically driven handling systems with companies such as Kaeser Kompressoren, Cooper Tools and Festo as well as institutes of the University of Stuttgart and the Fraunhofer Institute. Blue Competence of the VDMA The “Blue Competence” sustainability initiative of the VDMA has already led to significant improvements in efficiency in plant construction and engineering. Compared with the level of consumption in 2000, the products manufactured by the mechanical and plant engineering industry today are already allowing energy savings to be achieved which are equivalent to the electricity demand of all 48 million households in Germany, Austria and Switzerland. According to the VDMA, the use of innovative machinery and plants will allow these savings to be doubled in ten years. The various trade associations of the VDMA want to use Blue Competence to raise public awareness of energy efficiency and to highlight the savings being achieved by the technology leaders in industry.

How does Festo contribute to energy efficiency? Festo experts give their opinion …

Everyone must play a part Energy efficiency is more than just a concept. It must be an integral part of a company’s mission and vision. It affects every single employee in the company – whether they are in research and development, production, service or consulting. Here, Festo employees from different departments provide some insights.

With Festo Energy Saving Services, we are providing our customers with the tools to permanently reduce their energy consumption – from compressed air production through to application with professional analyses and optimisation concepts. The amortisation periods for our projects are no more than two years, and are often less than one year.

Energy efficiency has become an essential part of any production and assembly operation. All of our plants worldwide are working hard to deliver energy efficiency – starting at the factory and plant planning stage. The result is factories in which we consistently monitor our consumption data with an energy monitoring system or generate energy using sunlight. By taking such steps we are gradually becoming less vulnerable to the effects of rising energy prices.

Our customers in the process industries are also looking for energy-efficient solutions. A recent example is the wastewater treatment plant in Sindelfingen, which is now much more energy-efficient thanks to conversion to pneumatic automation solutions from Festo. Our customer has achieved electrical energy savings in the region of 10% for the operation of large pumps.

Christian Leonhard, Head of Global Factories Sven Lensdorf, Head of Service Management

Dr. Eckhard Roos, Head of Process Application Management

1.2012 trends in automation Impulse 20 – 21

At a time when energy prices are so high, successful facility management without giving consideration to energy efficiency is simply unthinkable. Solar cooling and the consistent use of compressor waste heat with adsorption chillers, the use of geothermal cooling and the deployment of highly efficient components are the cornerstones of our strategy for making our buildings energy-efficient. In EsslingenBerkheim alone, we are saving enough energy to supply power to 370 homes.

So how much do machine and plant engineering users actually save by implementing energy efficiency measures? What savings are achieved by the individual measures? The team of energy efficiency consultants at Festo has calculated the savings for a large number of applications in fields as diverse as body-in-white, food production, small parts assembly, electronics and process automation so that we can give our customers concrete and reliable figures.

Our customers in the Netherlands also value our support in the area of energy efficiency. Our training and consulting initiatives are helping many users to unlock the savings potential that lies hidden in their systems. This is not a phenomenon that is unique to my Dutch customers, however. General Managers of other Festo national companies are noticing a similar trend.

Bernd Bruy, Head of Technical Building Engineering Dr. Axel-Andreas Gomeringer, Head of Innovation and Technology Management

Thomas Pehrson, General Manager Festo Netherlands

A world first: The modular system for the fully automated in vitro production of skin models at Fraunhofer IPA, Stuttgart.

1.2012 trends in automation Impulse 22 – 23

Automated tissue engineering

Skin from the factory Until now, the production of biological tissue equivalents required expensive manual work and special laboratories. Four Fraunhofer Institutes have together developed the first fully automated, sterile system for producing tissue faster and in larger quantities.

T

he skin is the most important organ in the human body. The production of tissue models for testing medical treatments is therefore very complex. Until now, skin equivalents for transplants or for verifying the compatibility of active ingredients in medicines, cosmetics and chemicals were only produced manually on a laboratory scale. Culturing took a whole six weeks. Using this method, it was generally not possible to produce more than 2,000 pieces of skin per month, each measuring a square centimetre. This is certainly not the case in the new “Tissue Factory” at the BioPoLiS bioproduction laboratory of Fraunhofer IPA. It is the world’s first facility with fully automated in vitro production, producing up to 5,000 thumbnail-sized skin models per month. Seamless automation The facility for the production of skin equivalents is a flagship project in the area of bioproduction, which is the symbiosis of biology and automation technology. The interdisciplinary cooperation

between biologists and engineers led to an unprecedented degree of automation in tissue engineering. The seamless automation of all process steps facilitated the introduction of new production and financial standards such as reproducible quality, throughput and cost optimisation in skin model construction. Faster production To produce around 5,000 skin models per month, biological requirements with regard to the sterility of all processes and the handling of cells must be met. This involves a multi-stage process in which the skin samples are first sterilised, transported to the system by robot, broken down, isolated and cultivated in a special culture medium under constant ambient conditions. The cells are then grown in a 3D gel matrix in two layers. The skin equivalent is ready for use after just three weeks. In accordance with the principles of hygienic design, the developers of the tissue factory aimed for a continuous process chain. Cell extraction and proliferation as well as three dimensional tissue formation

are carried out in a seamless sequence in a single system. The process incorporates more than 100 Festo components, including compressed air preparation, sensors, cylinders, electric axes, servo and stepper motors as well as fastswitching valves and the valve series VUVG. The majority of these components are found in the cell extraction process. Where the products are part of the production space, clean room components are used. The decapper operates as a complete system and is responsible for unscrewing lids. Future-proof The bioproduction of tissue engineering products is already a hugely important area in biotechnology. It allows tissue to be produced in larger quantities and thus represents a major step forward in cell research. This new technology paves the way for an end to animal testing of products to check the skin tolerance level. In regenerative medicine, skin equivalents are helping an increasing number of people, for example with wounds that are not healing properly. In future, scientists

1.2012 trends in automation Impulse 24 – 25

Bioproduction par excellence: The new tissue factory produces up to 2.5 times more human tissue equivalent than before.

Automated tissue growth: Components from Festo in the cell extraction module, developed by Fraunhofer IPT.

Photos: Phot os: Frau raunhof nh f er/R er/Rafa er afae afa el Krrötz

want to do much more than just produce tissue. The automated technology needs to be further developed over the coming years so that other products such as cartilage can be produced automatically. www.festo.co.uk/laboratory

“The automated process is much easier to reproduce than manual work. The quality of skin produced with the tissue factory is therefore much higher.” Andreas Traube, Group Leader Bioproduction, Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), Stuttgart

Automation technology in Hungary

A country on the move In the summer of 1989, Hungary was the first central European country to open its strictly guarded borders. Just three months later came the fall of the Berlin Wall. Today, Hungary is proud to be a member of the European Union. Situated on the banks of the Danube, Hungary has developed into a major hub for the automotive industry and is a key location for Festo.

1.2012 trends in automation Synergies 26 – 27

Architectural masterpiece: The Chain Bridge in Budapest is the oldest and best known of the nine bridges crossing the Danube in Budapest.

H

aving once led the way in the development of the free-market economy in Central and Eastern Europe, Hungary was hit badly by the global economic crisis in 2008 and 2009. The high public deficit and levels of personal debt brought economic growth to a standstill in 2010. However, Hungary managed to weather the storm and is now on the road to recovery. A clear indicator of this are the high levels of investment by international groups of companies from the vehicle manufacturing and plant construction sectors. They are opening up new horizons for the country, with its wide lowland plains along the banks of the Danube. Bridge to the East No other country in Central Europe is so closely intertwined with other economies as Hungary. It generates 70 per cent of its national product through exports. Numerous international firms, most of them from Germany, invested around 60 billion euros in recent years and currently provide almost four out of

Festo Hungary Between 1979 and 1990, Festo was involved in a joint venture that developed and manufactured air preparation units for compressed air preparation. In 1991, the automation specialist then opened its own plant. Today, it is the central location for the manufacture of air preparation and vacuum technology products in the Festo global manufacturing network. With a workforce approaching 800, it is set to become the fourth largest Festo plant in 2012 thanks to the huge rise in worldwide demand for components for compressed air preparation, such as the MS series and safety valves. Also located on the same site is the Hungarian local sales company, which boasts an impressive client list including Audi, Daimler, Opel and GE.

Festo in Budapest: Local sales company for the Hungarian market and the central plant for compressed air preparation.

Booming MS series: Countless variants – manufactured according to the modular system – are made to order for customers all over the world.

Barnabás Bertalan, General Manager of Festo AM, the manufacturing company in Hungary

“We redesigned the plant so that we can respond quickly and flexibly to changes in the market.” every ten jobs in the private sector. Hungary’s central location and its close cultural and linguistic links with Germany and Austria are crucial factors for many German-speaking companies when choosing locations. The Land of the Magyar, as Hungary describes itself, acts as a bridge to the former Eastern Bloc countries. It offers high levels of productivity and a welleducated and motivated workforce, many of whom speak German and English fluently. German companies in the automotive and plant construction sectors have taken advantage of the favourable investment climate, transforming this small country of just under 10 million inhabitants into one of Europe’s key centres of industry in recent years. Both sectors together currently account for more than half of the country’s industrial production. “Vorsprung durch Technik” The Audi plant in the western Hungarian city of Györ is legendary. Located halfway between Vienna and Budapest, it produced its 20 millionth engine in April 2011. Audi Hungária has been part of the Volkswagen Group’s manufacturing network since 1993 and is the second largest company in Hungary. Automation technology from Festo has been there right from the very start and today ensures that the assembly plants operate efficiently. Audi Hungária employs more than 6,000 people and develops and produces engines for Audi AG and other makes in the Volkswagen Group. Every day, the plant produces 6,900 diesel and petrol engines with between four and twelve cylinders. The Audi TT Coupé and Roadster models as well as the A3 Cabriolet are also assembled here. The company plans to expand the assembly plant to incorporate the entire vehicle manufacturing process – including press shop, body construction and paint shop – by 2013. At around 900 million euros, this represents the largest single investment in Hungary to date. When completed, the plant will be capable of producing 125,000 vehicles every year, as compared with 38,000 in 2010. Audi will create a further 1,800 jobs in the process. Combined with the new distribution and supplier facilities, this will lead to the creation of a total of 15,000 jobs for the people of Györ. On the road to success Other car makes are also discovering the potential for development that exists in Hungary’s lowlands. Daimler AG has invested 800 million euros in the construction of a car plant in the southern Hungarian city of Kecskemét. Series production of the A-Class and B-Class is scheduled to begin here in 2012.

1.2012 trends in automation Synergies 28 – 29

Imposing landmark: The 268-metre long parliament building in Budapest.

General Motors is spending 500 million euros on the expansion of the Opel engine works in Szentgotthárd on the SlovenianAustrian border. In 2010 alone, Suzuki Hungária produced 170,000 vehicles in its plant in Esztergom, north of Budapest. According to Germany Trade and Invest (GTAI), the economic development agency of the Federal Republic of Germany (www.gtai.de), Bosch and Knorr-Bremse are two of the biggest automotive suppliers operating in Hungary, with both companies continuously putting in large sums of money. Continental Temic, Schaeffler and ZF are also active in Hungary. Most suppliers have their own local development operations. Alcoa, Delphi, Lear, Luk, Magna-Steyr and Philips are getting in on the act too. As part of the Daimler investment, a number of suppliers will be setting up operations directly at the new site in Kecskemét. The automotive industry and plant construction sector have recognised the potential of a motivated workforce combined with favourable economic conditions. International groups of companies are relying on the high levels of productivity in the Hungarian economy to help them to return to stable growth. Hungary is a small country with big opportunities.

Quality from Hungary: Not only does the engine for the Audi TT come from Hungary, final assembly of the vehicle also takes place here.

Marton Szövényi-Lux, General Manager of Festo Hungary

“Our market share of 50% shows that we are a strong and reliable partner for our customers.”

Model plant Audi Hungária: From 2013, up to 125,000 vehicles per year will roll off the assembly line in the 35,000 m2 hall.

Tool and product: Cutter head with spiral-cut bevel gear.

H Tooth by tooth Milling of bevel gears

Modern transmissions for cars and commercial vehicles must be able to withstand extreme loads and at the same time run quietly. This applies in particular to the spiral bevel gears used in drive systems, which must redirect the torque from the drive shaft by 90° to the axle shafts. In modern production machines, ready-to-install pneumatics from Festo deliver increased safety and shorter assembly times.

igh-quality spiral-cut bevel gears combine maximum load capacity with a low noise level and a high degree of efficiency. Like many components in the automotive industry, they are subject to demands for reduced weight combined with the smallest possible dimensions. Ever smaller bevel gears must guarantee the low-noise transmission of ever larger torques over hundreds of thousands of kilometres. Specialists in the area of bevel gear machine building like Klingelnberg GmbH depend on sophisticated production processes in order to guarantee maximum precision of the processing machine.

Smooth processes The manufacturing process in machines for bevel gear production begins with the setup process for the clamping device and the tool as well as the setup of automatic workpiece loading. The bevel gears are milled using cutter heads, which cut out the tooth gaps in the dry-cutting process. The bevel gears are then hardened and ground flat and rounded. The hard tooth flanks are ground or lapped depending on their purpose. Two hard finishing processes give the tooth flanks the properties needed for a long service life, low noise and energy efficiency. Large parts of the systems, which can be as big as a bus, are operated and controlled pneumatically at 6 bar. Time plays

1.2012 trends in automation Synergies 30 – 31

a hugely important role in the production process. That is why the company puts its trust in ready-to-install pneumatics from Festo. Fine-tuning of valves A central element is the ISO valve terminal VTSA. It is extremely compact and highly efficient thanks to its integrated pneumatic function and a mix of four valve sizes. To meet the specific safety requirements of the bevel gear milling machines C29 and C50, the VTSA had to undergo some fine-tuning. To protect workers against accidental start-up when working with large moving loads in the danger area, such as the cutter head, the valve functions for manual commissioning of the system were disabled for these areas. During maintenance and setup processes, the electrical voltage and the auxiliary pilot air of the pneumatic connection are switched off. Ready-to-install pneumatics In addition to improving safety, the ready-to-install pneumatic solution with the valve terminal VTSA offers significant time savings during assembly. The pre-assembled unit is easily put together and commissioned by the employees at Klingelnberg. Work that once took several days is now done in just a few hours. The ready-to-install solution from Festo was installed in more than 30 machines. All in all, the short installation time of just seven weeks per machine provides a decisive advantage. www.festo.com/catalog/vtsa

Global precision: Klingelnberg supplies manufacturing machines to customers all over the world.

Improved safety for employees: The function for manual commissioning was disabled in some areas of the valve terminal VTSA.

Klingelnberg GmbH Peterstraße 45 D-42499 Hückeswagen, Germany www.klingelnberg.de Area of business: Development and manufacture of machines for the production of spiral-cut bevel gears, measuring devices for axially symmetrical objects of all types, and the production of high-precision gear components made to customers’ orders

Saves valuable time: Ready-to-install pneumatics from Festo with the valve terminal VTSA.

New technologies in thin-film photovoltaics

Sunny side up For Oerlikon Solar, the outlook for thin-film silicon technology in photovoltaic modules is good. “We expect continued double-digit growth in the market,” says Michael Clauss, Product Development Manager of the Swiss company. Automation technology from Festo ensures secure handling of the large glass sheets.

Photos: Oerlikon Soll ar

1.2012 trends in automation Synergies 32 – 33

S

wiss company Oerlikon Solar owes its confidence not only to the continued growth of renewable energy, but also to its new TCO deposition system, a solution that it believes the market has been waiting for. TCO stands for “transparent conductive oxide”. The deposition system applies transparent, conductive zinc oxide layers on large glass sheets in six process chambers. These layers act as electrical contacts in the finished photovoltaic module. Before deposition, the glass is heated from room temperature to 200 °C in just 20 seconds. “The art is in creating an even temperature on the entire surface of the glass. This allows us to deposit homogeneous layers,” explains Clauss. Gentle movement The sheets of glass to be coated are transported to the process chambers on rollers. A pneumatic cylinder from Festo moves small metal pins, which raise the glass to various heights for deposition. The servopneumatic proportional valve MPYE controls all of the cylinders of the chambers, regulates the speed and approaches the various positions gently. The pneumatic cylinder is a temperatureresistant special design based on the compact cylinder ADN.

Sunny outlook: Thin-film photovoltaics at grid parity costs.

Impressive lift When the deposition process is completed, the glass moves to the exit lock. It is then returned from the vacuum back into the atmosphere. An automated lift moves the sheets to the next process step. The lift incorporates pneumatic axes DGC from Festo, while the axis ELGR ensures constant speed. “The Festo products used helped us to keep the system costs down,” explains Clauss. “A converter with electric motor would have been far more expensive.”

The new TCO deposition system applies electrically conductive, transparent coatings made from zinc oxide.

Energy used efficiently The TCO deposition system is part of the ThinFab™ production line. According to Oerlikon Solar, it allows production of renewable energy at grid parity costs for the first time. The future certainly looks bright for Oerlikon Solar with its silicon-based thin-film technology. The energy amortisation period is just under a year. A finished module consequently only needs to be used for less than one year for all the energy costs of the production process to be recouped. Wafer-based modules, on the other hand, require two to three years. In Oerlikon Solar’s view, the zinc oxide-based method is also better than other thin-film technologies, which use scarce and therefore expensive raw materials such as tellurium (cadmium telluride) or indium (CIS/CIGS) and can be problematic when it comes to disposal due to the toxicity of cadmium as a raw material.

Thin film outperforms wafer In an analysis conducted in 2010 by French investment bank BNP Paribas, thin-film photovoltaics were rated as a lower-cost technology compared with crystalline, wafer-based photovoltaics. It takes just a year for an investment in thin-film technology to be amortised, as compared to between two and three years for wafer-based systems. The energy yield is higher and thin-film modules generate more energy than wafer-based modules when there is less solar radiation. The performance of wafer-based modules deteriorates at high temperatures, but remains virtually constant in the case of thin-film modules. Production costs for thin-film modules are also lower in comparison with wafers.

The pneumatic components make the lift easy to adjust. The toothed belt axis for the guide is a ready-to-install unit for quick and simple construction. The axis has already successfully proven its reliability with a tested service life of 5,000 km. Nitrogen instead of compressed air A unique feature of the system is the open-loop and closed-loop control medium of the pneumatic system. Instead of using compressed air, Oerlikon Solar operates the TCO system with pure nitrogen. “We can thus keep the vacuum and gas supply system free of contamination,” says Clauss. “The pneumatic components, such as the MS series service units, tubing and fittings, also perform well with pure nitrogen.” Also included is the fast and dynamic flow sensor for liquids SFAW. It measures the flow rate, consumption and temperature of the water cooling in the system chambers. What makes this solution really clever is the ability of the sensor to control the volume of cooling water as required. More cooling water is supplied when temperatures in a process chamber are high and less when they are lower. The Festo sensor thus contributes to the efficient use of energy and has permanently reduced the operating costs of the system.

1.2012 trends in automation Synergies 34 – 35

The lift on the exit lock incorporates pneumatic axes DGC. The low-cost axis ELGR ensures constant speed.

Efficiently tempered: The flow sensor SFAW controls the amount of cooling water as required.

“In a project as challenging as the TCO deposition system, choosing the right automation partner is important. They must understand our requirements and contribute their own ideas.” Michael Clauss, Product Development Manager, Oerlikon Solar

100 football pitches The new TCO system represents a major leap forward compared with its predecessor: “With the second generation we have almost doubled the annual capacity. It coats 300,000 sheets of glass every year. This corresponds to around 100 football pitches,” explains Clauss. The maintenance and cleaning intervals have been extended by 75%. As each cleaning process means half a day of downtime, customers of Oerlikon Solar are thus able to significantly improve their productivity. “The productivity increases have been eagerly awaited by the manufacturers of thin-film modules,” says Clauss. But this is by no means the end of the Swiss company’s achievements. Oerlikon Solar

has broken the world record for the lowest module production costs with € 0.5 per Watt peak and stabilised efficiency of 11.9% in the champion laboratory cell with thin-film silicon technology. www.festo.com/catalog/elgr www.festo.com/catalog/dgc

Oerlikon Solar Ltd. Hauptstraße 1a CH-9477 Trübbach, Switzerland www.oerlikon.com/solar Area of business: Development and manufacture of tried and tested systems and turnkey production lines for the production of environmentallyfriendly thin-film solar modules

Improved material efficiency for packaging

Every gram counts The amount of waste produced in the manufacture of a single unit of tin packaging is no more than a few grams. However, when multiplying this by millions of units, it amounts to a considerable volume of valuable metal. Huber Packaging Group and Festo Didactic together managed to significantly improve material efficiency by conducting detailed material flow analyses.

L

ever lid cans or canisters are rarely regarded as valuable objects. They are mostly just a means to an end, such as for transporting and storing products. Once the paint, oil, cheese, beer or pickles have been used up, the packaging has fulfilled its purpose and is recycled. However, it should be remembered that behind every item of metal packaging lies an extensive and complex production process, which demands the highest levels of quality and efficiency.

Millions of euros worth of materials In order to be better able to meet demands for greater material efficiency, Huber Packaging Group GmbH participated in the VerMat programme of the German Materials Efficiency Agency

(demea) at two of its plants. The aim of the “Analysis of start-up and quality losses in component manufacturing” project was to identify potential for more economical use of tin and chrome plate and thus to make the company’s business processes more efficient. It proved to be an extremely worthwhile exercise. Huber Packaging Group processes tens of thousands of tonnes of tin plate to create metal packaging every year. This corresponds to a material value of tens of millions of euros. Putting processes to the test The manufacture of tin packaging produces a certain amount of waste from cuttings and rejects. To reduce these losses, Huber Packaging Group under-

took a detailed analysis of its production processes with Festo Didactic GmbH & Co. KG Denkendorf. Every lid, every base, every ring that did not meet the strict quality requirements was analysed. Were quality characteristics not met? If so, which ones? What were the reasons for poor quality and how could the problem be rectified? Over 100 tonnes saved Material flow analyses on selected production systems provided the basis for a sustainable improvement in efficiency. These analyses recorded the input material, the quantities and the weight of the good parts as well as the waste produced. The latter was further quantified to produce a summary in which

1.2012 trends in automation Synergies 36 – 37

“We were surprised at just how much material we were able to save.” Wolfgang Merkle, Head of INDUSTRIAL, Huber Packaging Group

the roots of the errors and their effects were evaluated. This detailed approach proved to be extremely successful in the case of Huber Packaging Group, as the material losses had many different causes. Potential savings of well over 100 tonnes of tin and chrome plate per year were identified on the basis of rela-

tively low levels of investment. For Huber Packaging Group, the decision to work with Festo Didactic has really paid off. All these small improvement measures have together helped the company to make significant changes. www.festo-didactic.com

Huber Packaging Group GmbH Otto-Meister-Straße 2 D-74613 Öhringen, Germany www.huber-packaging.com Area of business: Manufacture of tin plate metal packaging for chemical products, dyes, paint, foodstuffs and party kegs for the beverage industry

Russia

The Festo truck travelled around 8,000 kilometres on its tour of Russia.

Mobile customer service Festo Expotainer hits the road in Russia As part of a unique campaign, Festo brought the latest developments in pneumatics and electric drive technology directly to the world’s largest industrialised country. The Festo Expotainer took to the road in Russia for the first time in June 2011. On a tour that covered more than 8,000 km, the mobile technology showroom visited St. Petersburg, Moscow and 13 other cities. Over the course of four weeks, 36 tonnes of state-of-the-art automation technology rolled its way across the vast Russian landscape. Around 800 visitors showed up to see 14 dynamic applications featuring pneumatic and electric drives as well as the latest control and sensor technology. The cleverly designed 50 m² exhibition space also had wall displays featuring product examples and video presentations about the world of Festo technology. The Festo Expotainer was, as always, an amazing experience for everyone who came to see it – young talent interested in a career in technology, customers and interested companies alike. It was like a mobile bridge bringing innovations to various regions throughout the country, even the more remote ones. Such outstanding success deserves to be repeated, and so in 2012 the Festo Expotainer will spend an entire eight weeks on the road in Russia.

The Festo Expotainer visited 15 cities, starting with St. Petersburg.

Around 800 visitors got a chance to see the mobile technology showroom.

1.2012 trends in automation Festo worldwide 38 – 39

Greece

Booster boxes Pneumatics increase the degree of automation Fruit and vegetables look much more appetising and natural in wooden boxes. As a packaging material, wood does have some advantages over cardboard and plastic. This natural material has the benefit of being very strong at a low unladen weight, which remains constant during transport in refrigerated containers, even when subjected to variable ambient conditions such as air humidity, for example. That is why Greek firm NOURIS M. SONS O.E. has been specialising in machines for the manufacture of wooden boxes for packaging fruit and vegetables for many years. The degree of automation was increased gradually through the use of pneumatic components. They provide quick and accurate movement and ensure production capacities of up to 4,500 boxes per second. A recent addition is the Festo filter regulator MSB6-1/2. It features an integrated lock that makes oil supply easier. The new design with pressure gauge guarantees reliable operation of the service unit combination. In addition, valves from the MFH series, cylinders type DNC and ADVU components contribute to ensuring maximum reliability for the Greek company.

High-speed production: Automation technology from Festo proves its strength.

www.nouris.gr

China

Festo continues to expand Expansion of the plant in Jinan The economic boom in China has led to greater demand for automation technology. Production tends to be based in the region for the region. Reflecting this trend, Festo opened new production and logistics facilities at its Jinan plant on 21 March. This expansion will ensure that regional market demand in

China can continue to be met in the coming years. Jinan is served by the high-speed rail link between Beijing and Shanghai and is therefore an ideal location for future production growth.

Festo in Shanghai: In addition to the Festo company founded in 1993 there are branches in a further 33 cities in China.

Hungary

Magic squares: Electric drive technology from Festo produces cubes for “CubiCup”.

The magic pyramid Effortlessly precise electric drives 30 years ago, the Rubik’s cube had taken the world by storm. In the spirit of this much-loved puzzle, the Hungarian company Cubi Team Kft. developed the strategy game “CubiCup”, in which two players create a pyramid from 56 wooden cubes.

Precision, short cycle and retooling times: Electric axes, motors and controllers from Festo.

To ensure that the cubes fit together perfectly, the edge length of 17 mm must be cut to within an accuracy of one tenth of a millimetre. This is done using electric axes and controllers from Festo, which ensure absolute precision in the automated, highly efficient system. Apart from the quality of the end product, the automation solution guarantees short cycle and retooling times for different toys. A production changeover requires only a change in program along with the replacement of a few components, inserts and tools.

International

Twitter and Facebook Festo is expanding its Social Media presence Following the huge success of the YouTube channels, Festo is joining Twitter and Facebook in time for the Hanover Fair 2012. From the end of April, you’ll be able to access information about the company, its innovations, new products as well as career and education opportunities. You can also keep up-todate with news on events and trade fairs. Come and join us! We look forward to getting to know you.

www.festo.com/facebook

www.festo.com/youtube

www.festo.com/twitter

1.2012 trends in automation Festo worldwide/About this magazine 40 – 41

Germany

Hall of Fame Bionic Handling Assistant in the Deutsches Museum, Munich

About this magazine trends in automation 1.2012 May/June 2012

On 15 September 2011, the winner of the German Future Award 2010 earned a place in the “Hall of Fame” at the Deutsches Museum, thus joining the ranks of other major technological innovations. “We’re proud to make the Bionic Handling Assistent accessible to large numbers of people at the Deutsches Museum. We’re very pleased to be able to demonstrate to visitors the magnitude of the technological breakthrough which has been achieved by this project,” remarked award winner Dr. Peter Post from Festo at the ceremonial unveiling of the exhibition model. With the help of four sub-modules, visitors will experience exactly what it is that distinguishes the innovation developed by Festo and Fraunhofer, and be able to see the “trunk” of the Handling Assistant in action. The Bionic Handling Assistant is a pliant gripper arm whose structure and overall mode of operation are based on those of the elephant’s trunk. Its highly flexible nature makes it suitable for industrial and household applications allowing for safe interaction between people and technology. www.deutsches-museum.de/ausstellungen/ neue-technologien/zukunftspreis Publisher Festo AG & Co. KG Ruiter Straße 82 D-73734 Esslingen, Germany Tel. ++49 (0) 711 347 0 Fax ++49 (0) 711 347 20 71 [email protected] Project management Silke Gartenmeier, Customer Magazine Tel. ++49 (0) 711 347 39 02 [email protected]

Winners of the German Future Award 2010 with Prof. Dr. Wolfgang M. Heckl, Director General of the Deutsches Museum (centre), and Petra Maria Jung, Office of the Federal President.

Responsible for content Dirk Ebertz, Head of Marketing Instruments [email protected] Ralf Sohn, Head of Direct Marketing [email protected] Please note All terms such as customer, user, specialist or technical consultant refer to both men and women.

Copyright 2012 Festo AG & Co. KG All rights reserved.

The Bionic Handling Assistant exhibit: The gripper fingers are equipped with pressure sensors, making it possible for the assistant to grip objects more or less firmly as required.

All images, graphics and texts are protected by copyright law or other intellectual property rights. Any reproduction, modification or use in other print or electronic publications is prohibited without the express consent of Festo AG & Co. KG.

1.2012 trends in automation Soft Stop 42

Are you on target, Mrs. Klesmann? My work as an engineer in the Standard Design department requires creativity and concentration. The same can be said of field archery, which is a personal passion of mine. I consider inner calm along with the knowledge that I have acquired over the years to be the key to my success. However, there’s no way of guaranteeing that I’ll hit the target every time – either in archery or in 3D model design. There are simply too many variables to be taken into account. In field archery, you can spend up to seven hours on a course stretching over several kilometres and may find yourself having to assess the conditions as many as 24 times. How far away is the target? How does the terrain affect the path of the arrow? What are the wind and weather conditions like? And, most importantly, what is my physical and mental state? Even with 15 years of experience, two German Championship titles and fifth place in the European Championships under my belt, there is absolutely no guarantee of success. With each target, the adaptation and optimisation process begins anew. My work with 3D models is very similar, in that I must try to understand the product, the manufacturing process and the application process. Even the smallest deviation or minimal change in dimensions can have major consequences – both positive and negative. You have to know the product features and be able to think beyond the current situation and to look at it from a different perspective in order to identify new possibilities. Just like on a field archery course, you often have to approach your target slowly and gradually in order to hit the mark.

Highly modular Ideal for special purpose machine construction – valve terminal MPA-L. Simply choose the combination of individual components you need and then add or remove components as required.

www.festo.com

Photo: Torresol Energy

Powering change The Gemasolar solar power plant in Andalucia, with its 140-metre high concrete tower and a field containing 2,650 heliostats, is powering change. What makes this power plant revolutionary is not the heliostats or the central receiver, but the way in which energy is stored – flowing through the receiver and filling the tanks, which are 14 metres high and 36 metres wide, located at the base of the tower. Until now, solar technologies were restricted by the fact that they normally only generate electricity during sunlight hours. Gemasolar is the first large-scale solar power plant to use molten salt as a heat storage system. When heated to 565 degrees Celsius, it can provide electricity for 15 hours. Gemasolar can therefore supply power round the clock and not just when the sun is shining. The Spanish solar power plant is just one example of the intelligent use of energy. Industry initiatives such as Green Carbody or Blue Competence are setting the standard for greater energy efficiency worldwide.

Festo Corporation 395 Moreland Road P.O. Box 18023 Hauppauge, NY 11788 Phone 1.800.99.FESTO Fax 1.800.96.FESTO [email protected] www.festo.com/us